Eaton Crouse-hinds series User manual

Instruction Manual
Style3
RunwayCenterlineLight(RCL)L-850A
RunwayTouchdownZoneLight(TDZ)L-850B
PartNumberseries850X3-XX-XX
singlepiecealuminuminsetfixture
Copyright © 2019 Cooper Technologies Company
Forparts and technicalservice call(860)683-4300
DOCUMENT 2404
REVISION G
May 27, 2019
Eaton Crouse
-Hinds Series
1200 Kennedy Road
Windsor, CT06095

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1 Revisions
REV
LTR.
DESCRIPTION
CHK.
APV.
A
A204- 100
INITIALISSUE
KWF
JMM
B
A204-247
Corrected Headers on sheets 6-11
GFR
10/14/04
C A206-369
Revised title page copyright and deleted patent
pending; 6.2 was Taxiway Centerline Light L-
852B
PG 9/28/06
D A208-188
Paragraph 6.1 & 6.2, FAAAC 150/5345-46C was -
46B; 9 Parts List, item 4 was 21137-1, item 5 was
21137-2,
item 9 was 21115, item 19 was 10000-469 & added
25; Figure 6, revised to show item 25
PG 9/20/2008
E
A216-460
Revised manual format extensively; Part List, item 18
was 10000-468, Added safety symbols, Added items
26, 27 & 28.
IM
2/20/2017
F
A217-178
Updated section 2 ; added section 8.1, 8.2 & 8.3 ; In
section 9.4 torque of mounting screwswas 55-60 in-
lbs.
MA
10/26/17
G
A219-076
Revised Copyright to 2019; Updated section 8.2
extensively.
PG
5/27/19

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2 Product Warranty
Refer to Eaton’s Crouse-Hinds Airport Lighting Products Terms and Conditions for product
specific warranty information.

iv
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3 Safety Notices
3.1 KeepAway from Live Circuits
DANGER:
DANGER
Operatingandmaintenancepersonnelmustatalltimesobserveallsafetyregulations.
Donotperformmaintenanceoninternalcomponentsorre-lampwithpowerON.
3.2 Resuscitation
Maintenancepersonnelshouldfamiliarize themselveswiththetechniqueforresuscitationfoundinwidelypublished
manuals offirstaid instructions.
IMPORTANT:
IMPORTANT
SeeFAAAdvisoryCircularAC150/5340-26for additional information.
NOTICE:
NOTICE
Thisequipmentisnormallyusedorconnectedtocircuitsthatmayemployvoltagesthat
aredangerousandmaybefatalifaccidentallycontactedbyoperatingormaintenance
personnel. Extreme cautionshould be exercised whenworkingwiththisequipment.
Whilepracticalsafetyprecautionshavebeenincorporatedinthisequipment,the
followingrulesmustbestrictlyobserved.

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4 SAFETY SYMBOLS
WARNING:
WARNING
Thehazardorunsafepracticecouldresultinsevereinjuryordeath.
CAUTION:
CAUTION
Thehazardorunsafepracticecouldresultinminorinjury.
NOTICE:
NOTICE
Possiblydangerous situation, goods might be damaged.
IMPORTANT:
IMPORTANT
Helpfulinformation.
DANGER:
DANGER
Thehazardorunsafepracticewillresultinsevereinjuryordeath.

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5 Table ofContents
Title Page
………………………………………………………………………………….
i
1
Revisions
……………………………………………………………………………
ii
2
Limited ProductWarranty
…………………………………………………………...
iii
3
Safety Notices
……………………………………………………………………….
iv
4
SafetySymbols
…………………………………………………………………….
v
5
TableofContents
…………………………………………………………………...
vi
6
PartNumberExplanation– RCL / TDZ, L-850A/B
……………………………….
1
7
GeneralDescription– InsetStopBarLight,L-852S
……………………………….
2
7.1
RunwayCenterlineLight,L-850A
……………………………….
2
7.2
TouchdownZoneLight,L-850B
……………………………….
2
8
Installation
…………………………………………………………………………..
3
8.1
Installation
…………………………………………………...
3
8.2
InstallationBoltTorque
…………………………………………………...
3
8.3
Heico-lock Installation Guidelines (2014)
………………………………...
4
9
Maintenance
…………………………………………………....................................
4
9.1
Cleaning Lenses
…………………………………………………...............
4
9.2
Relamping
…………………………………………………........................
5
9.3
GasketReplacement
………………………………………………….......
6
9.4
Lens Replacement
…………………………………………………...........
6
9.5
Feed-thruReplacement
…………………………………………………....
7
9.6
Pressuretest
…………………………………………………....................
7
9.7
Cleanliness &Workmanship
………………………………………………
7
9.8
MaintenanceProgram
…………………………………………………......
7
10
PartsList
…………………………………………………..........................................
10
Figure1
19999 Installation(Lifting)Tool
…………………………………………….
9
Figure4
TopView ofFixture
…………………………………………………...........
11
Figure5
Side View ofFixture
………………………………………………….........
11
Figure7
BottomView ofFixture
…………………………………………………......
12
Figure8
InnerCoverLampBracketPositioning
…………………………………..
12
Figure9
Cut-away View ofFixture
…………………………………………………...
13

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6 Part Number Explanation –Runway Centerline / Touchdown Zone Light
850 3 - - -
FAA TYPE:
A = RUNWAY CENTERLINE LIGHT
B = TOUCHDOWN ZONE LIGHT
FAA STYLE:
COLOR FILTERS:
CC = CLEAR/CLEAR (L-850A)
CR = CLEAR/RED (L-850A)
RX = RED/BLANK (L-850A)
C = CLEAR (L-850B)
CX= CLEAR/BLANK
L-823 CONNECTION:
P1 = ONE PLUG ( BLANK COLOR UNITS WILL HAVE
A THREADED PLUG INSTALLED ON SIDE “B”
FEED-THRU ADAPTER)
P2 = TWO PLUGS ( L-850A ONLY)
BEAM ORIENTATION (L-850B ONLY):
L = LEFT TOE-IN
R = RIGHT TOE-IN
S = STRAIGHT

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7 General Description
7.1 Runway CenterlineLight,L-850A
The Crouse-Hinds Style 3 Runway Centerline Light is an ITS verified FAA L-850A per FAA AC
150/5345- 46C. It is designed for installation at the centerline of runways or any other location
where visualguidance of moving aircraft or ground vehicles is desirable. The fixture is designed to
fit on a FAA L-868, steel, Size B light base per FAA AC 150/5345-42(latest version), and have a
total height above grade/ground level of <.250 inch. The fixture is either uni-directional projecting
one beam of light, or bi-directional projecting two beams of light 180° apart. It is weatherproof and
will endure roll over loads without damage. The light fixture consists of an aluminum optical
assembly and a die cast bottom housing. The bottom housing is attached to the opticalhousing using
six screws.There is an integrated gasket that is bonded to the bottom cover to prevent water from
entering the assembled fixture. The fixture is mounted to a light base with six bolts (3/8-16 UNC
x7/8 lg., stn. stl.) and lock washers (3/8,stn. Stl.).One or two 32-watt,MR-16 lamps are secured to
brackets, which are fastened to the bottom housing. Electricalconnections are made at either one or
two feed-thru assemblies in the inner cover. The feed-thrus have ITSverified L-823 plugs for
connecting to FAA L-830/ L-831 Isolation Transformers. Lenses are held into the aluminum
housing with a bracket, gasket, molded elastomeric boot and two screws.The light beam color is
changed when it passes through the lens, which can be changed in the field.. All hardware is type
18-8 stainless steel. The complete light unit is 11.94 inches in diameter, 3.63 inches deep, and
weighs 12 lbs.
7.2 Touchdown Zone Light,L-850B
The Crouse-Hinds Touchdown Zone Light is an ITS verified FAA L-850B per FAA AC 150/5345-
46C. Its design is identical to the L-850A described in section 6.1.
Caution: Never handle the light assembly by the leads as this can break the waterproof seal

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8 Installation
8.1 Installation
The Style 3 RCL/TDZ light units are shipped complete, including the lamp(s), and are ready for
installation as received. Installation of a light unit is to be donewith primary POWER OFF and
SECURED. At each light location, install a steel, Size B, 12 inch deep minimum, L-868 Light Base
per FAA AC 150/5340-4 (latest revision). Install the light base with two opposite bolt holes
perpendicular to the runway centerline. Place the properly sized isolation transformer(s) in the light
base and make necessary primary power connections using L-823 connectors. The RCLlight unit
requires either two 45 watt, 6.6Asecondary transformersfor the two lead version, or one 100 watt,
6.6A secondary transformer for the single lead version. The TDZlight unit requires one 45 watt,
6.6A secondary transformer. Verify that the mounting flange on the light base is clean and the
O-ring (optional on deep cans) is coated with Dow Corning FS 1292 grease and is in place on the
light base. Connect the plug(s) from the light unit to the secondary(ies) of the previously installed
isolation transformer(s). Installation tool, Crouse-Hinds P/N 19999, will ease in the installation and
removalof the light unit (See Figure 1). The threaded eyebolts on the lifting tool screw into
threaded holes in the light fixture. Lower the light unit straight down onto the base. The light fixture
is subject to opticalmisalignment or mechanicaldamageif not seated properly. Verify the light
beam(s)/color/toe-in are properly orientated for the individual location. Secure the light fixture to
the base see section 8.2.
8.2 InstallationBolt Torque
•Usefully threaded,3/8-16bolts meetingrequirements ofFAAEB83A.(P/N 21716 is recommended.)
•UseHeico-LockorNord-Lock stainless steellock-washersperFAAspecifications*.
•Mountingbaseholesmustbedegreased,cleaned,anddriedpriortoboltinstallation.
•Base-to-fixturemating surfacesmustbedegreased,cleaned,anddriedpriortoinstallation.
•Applymarinegradeanti-seize (K=.18) permanufacturer’s instructions toeachbolt.
•Installthe3/8-16 bolts withlock-washersperlock-washermanufacturer’sguidelines.
•SeeSection 8.3 forHeico-Lockinstallation guidelines (2014)
•Achieveafullfinaltorqueof28FT-LBS (37.9 N-m) ±10% with acalibrated torquewrench.
•Impactwrenchesarenotrecommended as installation tools.
•Checktorqueandre-torqueallbolts within 2weeks of initial installation.
•Maintain allbolts bycheckingandre-torqueingperFAAspecifications*.
•If anylubricantsorthreadlockingcompoundsareused(notrecommended),torquemustberecalculatedbasedonK
factorprovided bylubricantorcompoundmanufacturer.
•Newbolts andlock-washersshallbeusedeachtimealightunit is removedfromits base.
*RefertothefollowingspecificationsforFAAinstallationandmaintenancerecommendations:
•AC150/5340-26 “MaintenanceofAirportVisualAids”
•AC150/5345-46 “Specification forRunwayand TaxiwayLightFixtures”
•FAAEngineeringBriefNo.83A “In-pavementLightFixtureBolts”

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WARNING:
WARNING
12” RCL/TDZ optical assembliesare designed to withstand a maximum torque of 28 ft-lb
(336 in-lb) perbolt, assuming K=.18 lubricant and appropriate superior-grade 3/8”
hardware, howeverother components within the light fixture installation (i.e. base-can,
extension rings, spacer rings, etc.) may not be capable of supporting such a load. Crouse-
Hindsrecommends following the installation bolt torque values and methodology outlined
in Section 8.2.
8.3 Heico-lock InstallationGuidelines (2014)
Step1:Handtightentoensurethat2-3threadsextendbeyondthenutonthrough-bolt applications.
Step2:Tighteneachbolttoone-thirdofthefinalrequiredtorquefollowingthepatternas shownbelow.
Step3:Increasethetorquetotwo-thirdsfollowingthepatternshownbelow.
Step 4:Increasethetorquetofulltorquefollowingthepatternshownbelow.
Step 5: Perform one finalpass on each boltworkingclockwisefrombolt1, atthefullfinaltorque
9 Maintenance
The preferred method of maintaining these lights is to periodically and systematically replace the
Optical Assembly and return it to the maintenance shop for renovation. As an alternative, the
Optical Assembly can beserviced in the field. However, it is recommended that field servicing be
limited to cleaning the lens as described in section 9.1 and to lamp replacements as described in
section 9.2.
9.1 Cleaning Lenses
With a compressed air blast or suitable brushes, remove allaccumulated debris from the light
channel. Clean the outer surface of the prism with a detergent solution. If the lens is coated with a
substance impervious to the detergent, a suitable solvent should be sparingly applied with a wad of
cotton or a patch of cloth on the end of a wood splint. After the solvent has acted the remaining
solvent and softened coating should be removed with a clean piece of cotton or cloth. Care should
be taken to avoid excessive contact between the solvent and the lens seal. Remove all remaining
solvent from lens and seal. A gentle air blast may be used.

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9.2 Relamping
Warning - Light assembly parts are hot when lamp is energized and remain hot
for a short time afterlamp/fixture isturned off.
Remove and secure powerto the fixture. Separate the fixture from the base by removing the six
bolts. Turn the fixture upside down and remove the six screws holding the inner cover to the
optical housing. Disconnect the lamp leads from the feed-thru terminals. Remove the Lamp
Assembly by gently pulling up on the lamp reflector base. Inspectthe feed-thruterminalfor signs
of corrosion. Replace feed-thru assemblies per paragraph 8.5. Clean the inside surfaces of the
lens(es) with denatured alcohol. Inspect the lamp holder bracket(s) forloose hardware; tighten the
mounting screws to 30 in-lbs.
Caution –Touching the quartz bulb with bare fingers may seriously shorten
lamp life. If the bulb hasbeen touched, wipe it clean with a piece of lens
cleaning tissue orsimilar material moistened with denatured alcohol.
Install the new lamp by reversing the procedure above. Make certain the rim of the reflector is
flush against the bracket and seated against the two pins at the bottom of the bracket. Connect the
lamp leads to the feed- thru terminals. Inspect/ replace the inner cover gasket per paragraph 8.3.
Assemble the inner cover onto the light housing. The screw hole patterns in the inner cover and
light housing are offset to insure proper alignment. Tighten the mounting screws to 30 in-lbs.
Perform a pressuretestas described in paragraph 9.6.
9.3 Gasket Replacement
Everytime the Optical Assembly is opened the gasket must be closely examined and replaced if
necessary. Any gasket that is stretched, torn, has a permanent set or some other defect, which
would prevent it from forming a watertight sealmust be replaced with a new gasket.
Note –A bad gasket seal is the most common cause of inset fixture leaks. It
is strongly recommended that a new gasket be installed every time the
Optical Assembly is opened.
Remove the old gasket from the groove in the inner cover. Carefully clean the flange mating
surfaces and the inner cover groove.This can be done by carefully scraping. Take care not to
damagethe mating surface and the bottom and sides of the groove. Coat the gasket (P/N 21140)
with a thin layer of Dow Corning FS 1292 Lubricating grease. Position the new gasket in the center
of the groove and press it into place. The grease will hold the gasket in place while the inner cover
is positioned on the light housing. Torque the inner cover screwsto 30 in-lbs. Performapressure
test as described in paragraph 9.6.

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Note – The groove is designed to be wider than the gasket. This provides
room for displacement of the gasket when compressed between the housing
and mating surface. Properly tightened screws are important in obtaining a
complete seal.
9.4 Lens Replacement
If a lens is broken, leaks or is badly pitted or scarred, it must be replaced. It is highly recommended
that this task be performed in a clean shop environment. Lens Replacement Kit P/N 21126-C or R
contains all necessary parts to change a lens. Remove andsecure power to the fixture. Separate
the fixture fromthe light base by removing the six bolts.Turnthe fixture upside down andremove the
six screwsholding the inner cover to the opticalhousing. Remove the wedge filter and bracket
assembly per paragraph 8.6. Remove the two mountingscrews and filter bracket assembly from the
opticalhousing. Remove the two lens retaining bracket screws from the optical housing.Removethe
lens-retaining bracket anddiscard the lens-retaining gasket. Firmly pushthelens/boot assembly from the
outside of the opticalhousing;discard the old lens andboot. Thoroughly clean the lens opening with
denatured alcoholand allow to dry. Inspectthe lens openingfor scratches or pits, a damaged lens
opening surface will not sealproperly. Place a new lens boot (P/N 21103) overthe replacement lens
(P/N 21102-C or R). Apply a thin coat of Dow Corning FS 1292 grease over the entire outside
surface of the lens boot. Align the lens/boot assembly in the lens opening and press it into place.
Verify that the lens boot is not pinched in the lens opening. Using a new lens retaining gasket (P/N
21101), fasten the lens retaining bracket (P/N 21100) to the light housing. Torque the mounting
screws to 55-60 in-lbs. Assemble the filter bracket assembly onto the opticalhousing per
paragraph 9.6. Assembly the inner cover onto the opticalhousing. The screw hole patterns in the
inner cover and opticalhousing are offset to insure proper alignment. Torque the mounting screws
to 30 in-lbs. Perform a pressure test per paragraph 9.6. Connect the fixture to the isolation
transformer(s), and place the fixture on the light base. Verify the light beam(s)/color/toe-in are
properly orientated for the individual location secure to light base per section 8.2.
9.5 Feed-thru Replacement
Remove and secure power to the fixture. Separate the fixture fromthe light base by removing the
six bolts. Turn the fixture upside down and remove the six screws holding the inner cover to the
optical housing. Disconnect the lamp leads from the feed-thru terminals. Remove the feed-thru by
unscrewing the retaining collar. Clean the mounting surface with IsopropylAlcoholand allow to
dry. Apply a thin coat of Dow Corning FS 1292 grease to the mounting flange of a new feed-thru
(P/N 21121 for 2 lamp/ 1 plug, or P/N 21122 for 1 lamp/ 1 plug). Apply a drop of Loctite 242 to the
feed-thru adapter threads. Screw the feed-thru retaining collar onto the adapter; refer to Figure 5 for
proper inner cover/ feed-thru orientation. Torque the retaining collar to 30 in-lbs. Assembly the
inner cover onto the opticalhousing. The screw hole patterns in the inner cover and light housing
are offset to insure proper alignment. Torque the mounting screwsto 30 in-lbs . Perform a pressure
test per paragraph 9.6. Connect the fixture to the isolation transformer(s), and place the fixture on
the light base. Verify the light beam(s)/color/toe-in are properly orientated for the individual
location. Secure to light base per section 8.2.

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9.6 Pressure Test
A light fixture should be subjected to a 20-psiair pressure test to verify that it is waterproof
whenever it has been opened or components have been replaced. Atire valve style pressure fitting
is located on the bottom of the inner cover. Pressurize the fixture to 20-psithen place it in a tub of
water or use a soap solution to locate escaping air bubbles. Carefully inspect the areas around the
lens, inner cover seal, and feed-thru adapter for leaks. Relieve the internal air pressure before
installing the fixture or attempting to repair a leak.
Note – Do not exceed 20-psi when pressure testing the fixture. Serious injury
and/or permanent damage to the fixture may result if a higherair pressure is
used. Once the pressure test is complete be sure to relieve the airpressure.
9.7 Cleanliness andWorkmanship
Service life depends upon the entire assembly being waterproof. All surfaces must be clean, dry and free
of all foreign matter if the light fixture is to operate for extended periods without requiring maintenance.
9.8 Maintenance Program
In order to insure maximum light fixture life, the installed units should be subject to a maintenance
program in accordance with the following:
A daily operation check should be made of the lighting fixture. The lights should be energized and
visually inspected. If any lamps are out, the location of the fixture should be recorded and the lamps
replaced at a time when the circuit is de-energized. (See Section 9.2 )
9.8.1 Regular cleaning is necessary in order to insure that inset lighting fixtures operate at maximum
efficiency. The lens and channel in front of the lens should be cleaned periodically with a soft
cloth and solvent. The weather and the location of the fixtures will dictate the regularity and type
of cleaning.
9.8.2 Snowplow operators should exercise extra care not to strike the light fixtures with snowplow
blades. After snowplow removaloperations, inspect alllight fixtures to locate and replace if
necessary, any damaged Light Assemblies. Passes over the light rows should be made with a
power broom only if practical. Whenever snowplows must traversein-pavement light fixtures,
they should be traveling at less than 5 mph or have the blades lifted clear of the fixtures.
9.8.3 The light is designed to exclude both ground and surface water from entering. If the lights are
not properly maintained (i.e., bolts tightened and seals in good condition) water may enter the
fixture. To prevent this from occurring, it is recommended that each fixture beinspected for the
presence of water at least once a month. More frequentinspection is desirable during and
following rainyseasons.

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9.8.4 Optical Assembly hold-down bolts should be checked for proper torque per section 8.2. Light
fixtures in and around the TouchdownZone area are especially prone to vibration damage if the
mounting bolts are not properly torqued. The mounting surface of the light base must be clean
and free of foreign matter when checking mounting bolts.
9.8.5 If a fixture contains water, the water should be removed and the entire fixture cleaned and dried.
Perform a pressure test per paragraph 9.6to locate the source of the leak. Replace the bottom
cover gasket (P/N 21140). See Section 9.3.

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Figure 1 19999 Installation(Lifting) tool

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10 PartsList
ITEM
PART
NUMBER
850A3-CC
QTY
850AC -
CR
QTY
850A3-RX
QTY
850B3-C
QTY
850BC -C X
QTY
DESCRIPTION
1
21100
2
2
2
1
2
BRACKET,LENS RETAINING,18-8STNSTL
2
21126-C
2
1
0
1
1
CLEARLENS,REPLACEMENT KIT(LENS,
GASKET, BOOT, SILICONE,GREASE)
3 21126-R 0 1 1 0 0
RED LENSREPLACEMENT KIT(LENS,GASKET,
BOOT, SILICONE, GREASE)
4
21137-9
0
0
0
1
0
OPTICAL HOUSING, MACHINED, TDZ, ALUMINUM
5
21137-7
1
1
1
0
1
OPTICAL HOUSING, MACHINED, RCL,ALUMINUM
6
21143
0
0
1
0
1
GASKET,BLANK COLOR, LENSRETAINING
7
21109
0
0
1
0
1
FEED-THRU PLUG, ALUMINUM
8
21140
1
1
1
1
1
GASKET, BOTTOMCOVER
9
21461
2
2
1
1
1
LAMPBRACKET ASSEMBLY, 18-8 STNSTL.
10
21116
2
2
1
1
1
LAMP/REFLECTORASSEMBLY48 W,6.6A
11
21138-1
0
0
0
1
0
BOTTOM COVER, MACHINED, TDZ, ALUMINUM
12
21138-2
1
1
1
0
1
BOTTOM COVER, MACHINED, RCL, ALUMINUM
13
21120
2
2
1
1
1
ADAPTER,THREADED,FEED-THRU
14
21121
A/R
A/
R
A/R
A/R
A/R
FEED-THRU ASSEMBLY2 LAMPS,1 PLUG
15
21122
A/R
A/
R
A/R
A/R
A/R
FEED-THRU ASSEMBLY1 LAMP,1PLUG
16
10035-61
2
2
2
1
2
O-RING, FEED-THRU ADAPTER
17
10000-471
1
1
1
1
1
SCREW, SEMS,PANHDTYPE 1ACROSS,
GREEN, #10-32X3/8LG,18-8STNSTL
18
10000-548
4
4
4
2
4
SCREW, SOCKET HEADCAP, #10-32X 7/16LG
19 10000-517 12 12 6 6 6
SCREW, SEMS,PANHDTYPE 1ACROSS,#8-32
X5/16 STNSTL
20
10000-400
6
6
6
6
6
SCREW, HEXWASHER HEAD/DRI-LOC,
#10-32X3/8 LG,18-8 STNSTL
21
21148
2
2
1
1
1
BRACKET,LAMPMOUNTING
22
10037-795
1
1
1
1
1
FITTING,PRESSURE TEST,1/8– NPT
23
10048-25
A/R
A/
A/R
A/R
A/R
SILICONEGREASE
24
10048-106
A/R
A/
R
A/R
A/R
A/R
PIPESEALANT PASTE
25
21454
6
6
6
3
3
STANDOFF, LAMP MOUNTING
26
11A22-019D
1
1
1
1
1
WASHER,LOCK,INTERNALTOOTH,TYPE A,#10,
STNSTL, PASSIVATED
27
10047-3141
1
1
1
1
1
GROUNDING TERMINAL, SOLDERLESS, 4-14AWG,
ALUMINUM
28
11A01-019D
1
1
1
1
1
WASHER,PLAIN,TYPE A,#10, 18-8 STNSTL,
PASSIVATED

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Figure 2 Top View of Fixture
Figure 3 Side Viewof Fixture

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InstructionManual
Style 3
RunwayCenterline,TouchdownZone
singlepiecealuminuminsetfixture
12
Figure 4 Bottom View of Fixture
Figure 5 Inner Cover LampBracket Positioning

Document 2404
Rev. G
InstructionManual
Style 3
RunwayCenterline,TouchdownZone
singlepiecealuminuminsetfixture
13
Figure 6 Cut Away View of Fixture